Air access panel

ABSTRACT

A panel for a covering an air access opening formed in a component of a ventilation system, comprises a one piece rectangular peripheral frame defining a panel opening, said frame having a front side and a rear side, and upper, lower and side frame elements, a plurality of parallel louvers extending between opposite side frame elements of the frame, across said panel opening. The louvers are integrally formed with the frame. The panel is formed from pressing a blank of at least 20 gauge steel by CNC punching, or hydraulic shearing or using a progressive dye. A door having a front side and a rear side, may be removably and pivotally attached to an upper portion of the panel, pivotal from an open position allowing access to the panel opening to a closed position wherein the door covers an upper portion of the panel opening. Preferably the door is attached to the panel by a slot and pin arrangement.

BACKGROUND OF THE INVENTION

The present invention relates to a panel utilized for covering an air access opening in the ventilation system.

Ventilation systems such as air conditioning systems, heating systems, or any other system requiring the movement of air, require the return of air into the system via an opening in a component part of the system. In order to control return air flow and to prevent foreign matter from entering the ventilation system, it is known and desirable to place a panel over the air access opening in the system, the panel typically including a plurality of horizontally extending parallel louvers extending across the return air access opening. In order to filter the air returning into the system, it is also known to place an air filter behind the louvers. Such known panels are typically formed by a plurality of separate components. Such known panels are often formed of a four piece frame, assembled together with corner brackets. Louvers are typically individual pieces that are each attached to the panel frame to form a louvered grill to cover the panel which is positioned to cover the air access opening. Because the louvers and frame elements are separate pieces, the louvers may tend to vibrate as air passes through the grille. Furthermore, typically, the air access opening of the system and panel covering same is placed adjacent to the ground, and thus may be exposed to incidental collisions from office equipment, household furniture or inadvertent human activity. Once impacted, such known individual louvers tend to bend, become indented and/or are prone to disengagement from the panel, thereby leaving exposed the space behind the panel or potentially the electrical components in the ventilation system positioned behind the panel.

It is further known to provide a door for covering a portion of the panel. Typically, the door is pivotally joined to the panel frame, typically to an upper portion of the frame, such that the door covers an upper portion of the panel, above the louvered portion thereof. The door may be pivoted upwardly to open same and allow access through the panel and thereby gain access to the ventilation system, for servicing and the like. To do so, the door must be held open either by hand or with the addition of further support pieces to the panel.

Known air access panels for ventilation systems do not function as efficiently as necessary for optimal utilization. Furthermore, known access doors used with air access panels do not function with maximal convenience or efficiency. As such there is a need for an improved air access panel for use in ventilation systems.

SUMMARY OF THE INVENTION

It is an object of the invention to provide an improved air access panel.

In accordance with an aspect of the invention there is provided a panel for a covering an air access opening formed in a component of a ventilation system, said panel comprising a one piece rectangular peripheral frame defining a panel opening, said frame having a front side and a rear side, and upper, lower and side frame elements, a plurality of parallel louvers extending between opposite side frame elements of the frame, across said panel opening, said louvers integrally formed with the frame, said plurality of louvers forming a louvered portion of the panel.

Preferably the panel is formed from pressing a blank of at least 20 gauge steel by CNC punching or hydraulic shearing. Alternately, it may be formed using a progressive dye.

In accordance with a further aspect of the invention, there is provided a panel for a covering an air access opening formed in a component of a ventilation system, said panel comprising a rectangular peripheral frame defining a panel opening, said frame having a front side and a rear side, and upper, lower and side frame elements, a plurality of parallel louvers extending between opposite sides frame elements, across said panel opening, said plurality of louvers forming a louvered portion of the panel; and a door having a front side and a rear side, said door being removably attached to an upper portion of the panel, said door pivotal from an open position allowing access to an upper portion of the panel opening to a closed position wherein the door covers said upper portion of the panel opening. Preferably the door is attached to the frame by a slot and pin arrangement connecting the door to the panel.

Advantages which may be provided with the panel of the herein invention include: a reduction in production steps to produce the panel, a reduction in vibratory noise emitted by the panel, and a reduced tendency to have a louver be accidentally removed from the panel. The removable door adds to the convenience of the use of the panel.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:

FIG. 1 is a perspective view of an example embodiment of a panel of the herein invention with a door attached thereto;

FIG. 2 is further perspective view of an example embodiment of a panel of the herein invention with door separated therefrom;

FIG. 3 is a front view of an example embodiment of a panel in accordance with the invention, inserted within an air access opening of a component of a ventilation system;

FIG. 4 is a side view of the example embodiment of the invention of FIGS. 1 to 3;

FIG. 5 is a top view of the example embodiment of FIGS. 1 to 4; and

FIG. 6 is a perspective view of a further example embodiment of the invention.

Like reference numerals are used throughout the Figures to denote similar elements and features.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS OF THE INVENTION

As shown in FIGS. 1 to 5, an example embodiment of a panel 10 for a covering an air access opening 12 formed in a component of a ventilation system 14, comprises a one piece rectangular peripheral frame 16 defining a panel opening 28. The frame has a front side 18 and a rear side 20, and upper 22, lower 24 and side 26 frame elements.

A plurality of parallel louvers 30 extending louvers extend horizontally across a bottom portion of said panel opening 28 between opposite side frame elements 26, across said panel opening. The louvers 30 are integrally formed with the frame 16, and the plurality of louvers form a louvered portion 32 of the panel 10.

A mounting flange 34 is integrally formed with and extends rearwardly from the rear side 20 of said peripheral frame and is adapted to fit within the air access opening 12 for mounting of the panel on the ventilation system component 14. Mounting flange 32 may be attached thereto by any suitable securing means, such as screws, rivets or the like. Rearwardly extending mounting flange 32 is also integrally formed with the peripheral frame 16. Preferably the mounting flange extends rearwardly from the frame members approximately 1.5 inches.

A filter guide 36 is secured, preferably by spot welding, to the rear of the panel 10. The guide 36 is adapted to hold an air filter in place behind the louvered portion 32 of the panel. The guide may be secured to the lower portion of the panel by attachment to the to the frame 16 or the mounting flange 34. Filter guide 36 forms a carrying channel for a supporting an air filter 37 to be disposed between the louvered portion 32 and the air access opening 12, covering the entire air access opening, and thereby filtering air passing through the air access opening 12, returning to the ventilation system.

As shown in FIG. 2, the panel 10 has a length L as measured from an upper edge of the frame to a lower edge of about 50 inches, a width W of about 16 inches as measured from side edge to side edge of the frame and a depth measured from front to back, including the mounting flange of about 1.5 inches. The louvered portion extends from the bottom of the panel opening, upwardly about 18 inches. It should be understood that dimensions of the panel may be varied to accommodate different sized air access openings having varying airflow requirements of ventilation equipment.

The panel 10 is preferably formed by machine punching of a steel blank into the panel and louvered portions, the louvers being integrally formed with and being permanent and constituent elements to the one piece frame. In particular, the panel frame 16 with louvers 30 and mounting flange 34 are preferably formed from the steel blank by cutting and punching to desired dimensions with hydraulic shears and/or CNC (computer numerically controlled) punch machines and/or a progressive dye. Pins 52 are pressed onto the panel of the access panel frames.

Preferably twenty four (24) louvers 30 form the louvered portion 32 of the panel, extending horizontally in parallel across the frame 16. Preferably each said louver 30 is angled downwardly from front to back. It should be understood that the louvers may be angled in an opposite orientation, i.e. angled downwardly from back to front. The number and size of the louvers 30 may vary as panel dimensions are modified to custom fit various ventilation units having different sized air access openings for various air flow requirements.

Panel 10 is preferably formed from steel sheet having a thickness of at least 20 gauge, preferably with a satin coat material. Although other materials may be substituted, this minimum thickness is preferred to ensure sufficient strength of the frame. It should be understood that thickness may vary for different sized ventilation equipment and applications if required.

A door 42 may be removably and pivotally attached to the panel 10. The door may be removably attached to an upper portion of the panel 10, pivotable from an open position, shown in FIGS. 1 and 4 to a closed position wherein the door covers the upper portion 40 of the panel opening. The door has a front side 44 and a rear side 46, and side edges 48. Preferably, the door 42 may be formed from a 22 gauge thickness steel sheet formed by hydraulic shearing and/or CNC punching, bending to desired shape and specifications as shown in the drawings. It may also be formed using a progressive dye, whereby the door is formed by the insertion of a steel blank in a suitable dye which presses the panel. In the example embodiment shown in the drawings, the door has an approximate length of 29.5 inches a width of 13.75 inches and the side edges have a depth from front to back of approximately 1 inch.

In the embodiment of FIGS. 1 to 5, opposite side edges 48 of the door each forms a slot 50 extending forwardly and upwardly from the rear of the side edge on each said opposite side edge at an upper portion thereof. The slots 50 are preferably formed by punching same during the forming process of the door. In the example embodiment, the slots 50 extend at an angle α of approximately 132 degrees upwardly from the rear of the door forwardly on the side edges thereof. This angle may be varied as desired. Mounting flange 34 extends rearwardly from the frame 16, at least along each side element 26 of the frame. Mounting flange includes pins 52 positioned on the mounting flange at upper portions on each side frame element thereof. Each pin 52 extends inwardly and substantially horizontally into the panel opening 28 and each is adapted to be inserted into the respective mating slot 50 on the side edges 48 of the door. Thus, the slots 50 act as hooks, located on opposite sides of the door for carrying the door on the frame in pivotal removable engagement therewith. The door is pivotable from the closed position wherein, when the pins 52 are inserted in slots 50, the door rests sitting flush with the front of the frame, covering the upper portion 40 of the panel opening 28, above the louvered portion 32 thereof. The door may be pivoted upwardly to an open position, as shown in FIGS. 1 and 4 to allow access to the panel opening 28.

It should be understood that the although the embodiment of FIGS. 1 to 5 shows slots 50 are positioned on the side edges 48 of the door with mating pin 52 on the mounting flange 34 of the frame, an opposite arrangement may be utilized. Shown in FIG. 6, in an alternate example embodiment of the invention, each side frame element 26 forms a rearwardly and downwardly extending slot 54 at an upper portion of each side frame element, and the door includes pins 56 extending inwardly on each side edge 48 thereof, the pins 56 being sized and positioned to be inserted within each slot 54, thereby carrying the door on the frame in pivotal removable engagement therewith.

The door 42 shown in FIGS. 1 to 5 and 6 is easily removable, simply by lifting the door upwardly and outwardly so as to disengage the pins 52, 56 from slots 50, 54, respectively. Having the door be removable may be preferable to a non removable hinged door as are typical in prior art air access panels, since holding the door open while accessing the interior of the equipment is either inconvenient or requires additional support pieces.

In operation, preferably the panel 10 is positioned within a ventilation opening of a component of a ventilation system. Examples of components to which the panel may be attached are: furnace or fan coil or any other component of a ventilation system requiring the return of air thereto. The frame and the mounting flange extending rearwardly therefrom are sized to be snuggly fit within the inner walls of the ventilation component defining a ventilation opening. The mounting flange, can then be removably secured to the ventilation equipment inner wall by any suitable means such as rivets, screws or the like. It should be understood that the term ventilation systems is meant to be interpreted broadly and encompasses any system or part thereof which includes an air access opening in at least a component thereof to allow the flow of air therethrough. Such ventilation systems include any type of air movement system, air heating, air cooling and/or air conditioning systems in any type of equipment or application.

The above-described embodiments of the present invention are intended to be examples only. Alterations, modifications and variations may be effected to the particular embodiments by those skilled in the art without departing from the scope of the invention, which is defined by the claims appended hereto. 

1. A panel for a covering an air access opening formed in a component of a ventilation system, said panel comprising: a one piece rectangular peripheral frame defining a panel opening, said frame having a front side and a rear side, and upper, lower and side frame elements; and a plurality of parallel louvers extending between opposite side frame elements of the frame, across said panel opening, said louvers integrally formed with the frame, said plurality of louvers forming a louvered portion of the panel.
 2. A panel as recited in claim 1 wherein a mounting flange is integrally formed with and extends rearwardly from the rear side of said peripheral frame and is adapted to fit within the air access opening for mounting of the panel to the component, such that the panel covers the air access opening.
 3. A panel as recited in claim 2 wherein said plurality of louvers extend horizontally across a bottom portion of said panel opening and are positioned to cover the air access opening when the panel is mounted to the component.
 4. A panel as recited in claim 3 wherein a filter guide is secured to the rear of the panel behind the louvered portion of panel, said filter guide forming a carrying channel for a supporting an air filter to be disposed between the louvered portion and the air access opening, covering the entire air access opening, for filtering air passing through the air access opening.
 5. A panel as recited in claim 2 wherein said panel comprises steel.
 6. A panel as recited in claim 5 wherein said panel comprises steel of at least 20 gauge.
 7. A panel as recited in claim 2 wherein said panel has a length as measured from an upper edge of the frame to a lower edge of about 50 inches and a width of about 16 inches as measured from side edge to side edge of the frame.
 8. A panel as recited in claim 7 wherein the louvered portion extends from the bottom of the panel opening, upwardly about 18 inches.
 9. A panel as recited in claim 6 formed by pressing and bending a steel sheet into the desired shape of the panel.
 10. A panel as recited in claim 2 wherein each said louver is angled downwardly from front to back.
 11. A panel as recited in claim 2 wherein said mounting flange is sized to be inserted into the air access opening so as to be positioned against walls of the ventilation system component which define the air access opening, and which may be removably attached thereto by securing means.
 12. A panel as recited in claim 2 further comprising a door having a front side and a rear side, said door being removably attached to an upper portion of the panel, said door pivotal from an open position to a closed position, wherein the door covers a portion of the panel opening.
 13. The panel as recited in claim 12 wherein the door includes opposite side edges each of which forms a slots extending forwardly and upwardly from the rear of each side edge at an upper portion thereof, the mounting flange extending along each side element of the frame and each including a pin positioned on opposing upper inner sides of the mounting flange, each pin extending inwardly and substantially horizontally into the panel opening and being adapted to be inserted into the respective mating slot on the side edges of the door, thereby carrying the door on the frame in pivotal removable engagement therewith.
 14. The panel of claim 13 wherein the slots extend at an angle α of approximately 132 degrees upwardly from the rear of the door forwardly on the side edges thereof.
 15. The panel as recited in claim 12 wherein the door in a closed position covers an upper portion of the panel opening, above the louvered portion.
 16. The panel as recited in claim 12 wherein each side frame element forms a rearwardly and downwardly extending slot at an upper portion of each side frame element, and the door includes pins on each side thereof, sized and positioned to be inserted within each said slot, thereby carrying the door on the frame in pivotal removable engagement therewith.
 17. A panel for a covering an air access opening formed in a component of a ventilation system, said panel comprising: a rectangular peripheral frame defining a panel opening, said frame having a front side and a rear side, and upper, lower and side frame elements, a plurality of parallel louvers extending between opposite sides frame elements, across said panel opening, said plurality of louvers forming a louvered portion of the panel; and a door having a front side and a rear side, said door being removably attached to an upper portion of the panel, said door pivotal forwardly from an open position allowing access to an upper portion of the panel opening to a closed position wherein the door covers said upper portion of the panel opening.
 18. A panel as recited in claim 17 wherein said panel frame and louvers are one integrally formed piece and said louvers are positioned at a lower portion of the panel opening, below the door when in said closed position.
 19. A panel as recited in claim 17 wherein a mounting flange is integrally formed with and extends rearwardly from the rear side of said peripheral frame and is adapted to fit within the air access opening for mounting within the air access opening of the ventilation system component.
 20. A panel as recited in claim 17 wherein said panel comprises steel of at least 20 gauge.
 21. A panel as recited in claim 19 wherein said mounting flange is sized to be inserted into the air access opening so as to be positioned against walls of the ventilation system component which define the air access opening, and which may be attached thereto by securing means.
 22. The panel as recited in claim 17 wherein the door includes opposite side edges each of which forms a slot extending forwardly and upwardly from the rear of each side edge at an upper portion thereof, the mounting flange including portions extending along each side element of the frame and each including a pin positioned on opposing upper inner sides of the mounting flange, each pin extending inwardly into the panel opening and being adapted to be inserted into the respective mating slots on the side edges of the door, thereby carrying the door on the frame in pivotal removable engagement therewith. 